Power steering pump, 6-cylinder gasoline engine

Transcription

1 Volkswagen Touareg - Power steering pump, 6-cylinder gasoline engine Page 1 / Power steering pump, 6-cylinder gasoline engine There is no provision for servicing the power steering pump. If complaints are received determine cause with the help of pressure tests and leakage test. If a malfunction exists replace power steering pump. Note: If reservoir fluid level is low then check steering system for leaks. In the case of leaks at the line connections first tighten connections and wipe dry then recheck for leaks. Power steering pumps supplied as spare parts and are not filled with oil. They must be filled with hydraulic fluid G and to rotate pump by hand, otherwise the power steering pump may be damaged or be noisy during operation. Type of fluid: Hydraulic fluid G Power steering pump delivery pressure, 6-cyl. gasoline engine, checking

2 Page 2 / 11 Special tools, testers and auxiliary items required Hose clamp 3094 Power steering test unit V.A.G 1402 Adapter V.A.G 1402/2 Hose from adapter set V.A.G 1402/6 Special tools, testers and auxiliary items required

3 Page 3 / 11 Adapter V.A.G 1402/4 - Remove sound insulation for engine Repair Manual, Body Exterior, Repair Group 50, Sound insulation, installation overview - Clamp off intake hose with hose clamp Remove pressure line at pump.

4 Page 4 / 11 - Assemble adapters as shown in illustration. 1 - Power steering test unit V.A.G Adapter V.A.G 1402/2 3 - Adapter V.A.G 1402/4 4 - Hose from adapter set V.A.G 1402/6 5 - Banjo bolt 6 - Seal ring - Remove hose clamp 3094 from intake line. Make sure that the lever on pressure gauge is in position

5 Page 5 / 11 - Start engine and top off hydraulic fluid in reservoir if necessary. - Turn steering wheel from lock to lock about 10 times. - Check delivery pressure. Test conditions: V-belt/V-belt tension OK System has no leaks Hoses/lines not kinked or restricted - With engine idling, close shut-off valve (position ) for no longer than 5 seconds and note pressure. Specifications: 110 to 120 bar If pressure is not to specification, replace power steering pump 48-4, Power steering pump, 6-cyl. gasoline engine, removing and installing. - Remove pressure gauge and adapter. - Bleed steering system 48-7, Bleeding steering system. - Inspect hydraulic oil level and top off if necessary Repair Manual, Maintenance

6 Page 6 / Check steering system for leaks 48-7, Steering system, checking for leaks. Power steering pump, 6-cyl. gasoline engine, assembly overview Note : Replace sealing rings Do not reuse drawn off hydraulic oil. Hydraulic fluid: G Banjo bolt, 40 Nm Seal rings, 16 x 22

7 Page 7 / 11 Always replace Pressure hose Intake hose Spring clamp Power steering pump Check delivery pressure 48-4, Power steering pump delivery pressure, 6-cyl. gasoline engine, checking Fill with fluid before installation Removing and installing 48-4, Power steering pump, 6-cyl. gasoline engine, removing and installing Shim Belt drive pulley Internal hex bolt, 25 Nm Hex bolt, 25 Nm Bracket Power steering pump, 6-cyl. gasoline engine, removing and installing Special tools, testers and auxiliary items required Hose clamp 3094

8 Page 8 / 11 Torque wrench V.A.G 1331 Hex bolt M8 x 50 Removing - Remove engine sound insulation Repair Manual, Body Exterior, Repair Group 50, Sound insulation, installation overview - Mark direction of rotation of ribbed belt - Screw M8 x 50 bolt into threaded hole on tensioner until ribbed belt is no longer under tension. - Remove power steering pump ribbed belt pulley. - Remove belt.

9 Page 9 / 11 Note: When removing pump pulley, observe shim located behind it. It is important for the measurement and adjustment of power steering pump. Do not remove shim from pump gear yet. - Clamp off intake hose with hose clamp Remove banjo bolt. - Close off pressure line/hose with a plastic bag or similar. - Open spring clamp and pull intake hose off the power steering pump. - Unbolt power steering pump and remove. - Measure dimension -a-. The shim is included in the measurement. - Make a note of measurement. Installing Installation is reverse of removal, with special attention to

10 Page 10 / 11 the following: - Measure dimension - a - on new power steering pump with the shim. - Make a note of the measurement. - Calculate thickness of shim 48-4, Calculating shim thickness. - Fill pump with hydraulic fluid. Fill pump with fluid through intake line. - Turn the hub by hand until oil runs out of the pressure side. - Install power steering pump. - Bleed steering system 48-7, Bleeding steering system. - Check hydraulic fluid level. Repair Manual, Maintenance - Check steering system for leaks 48-7, Bleeding steering system. Calculating shim thickness - Calculate shim thickness using values measured. Example: Measurement of old pump with shim mm - Measurement of new pump without shim mm Thickness of shim = The following shims are available: 0.80 mm

11 Page 11 / 11 Thickness (mm) Shim application Electronic Parts Catalog "ETKA" - Install power steering pump. Tightening torques Power steering pump to bracket Belt pulley to power steering pump Banjo bolt to power steering pump 25 Nm 25 Nm 40 Nm